Low Carbon Vehicle Technology Project Benchmarking and Teardown Activities Undertaken on Nissan Leaf and Chevrolet Volt

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1 Low Carbon Vehicle Technology Project Benchmarking and Teardown Activities Undertaken on Nissan Leaf and Chevrolet Volt Johnathan Breddy, Tata Motors European Technical Centre (TMETC) plc

2 Agenda Benchmarking and teardown overview NVH challenges of alternative powertrains Nathan Gabbott, TMETC Thermal benchmarking David Bridge, MIRA

3 Car Selection UK-specification Nissan Leaf US-specification Chevrolet Volt

4 Timeline Leaf 1 Delivery Benchmarking 2 Delivery Benchmarking Teardown Volt 1 Delivery Benchmarking Vehicle energy efficiency evaluation 2 Delivery Benchmarking Teardown 211 Jun Jul Aug Sep u u u u Oct Nov Dec 212 Jan Feb

5 Benchmarking Activities Subjective Assessments Aerodynamics Braking and vehicle stability Parasitic losses Discharge behaviour Energy efficiency Thermal NVH

6 Subjective Assessments

7 Subjective Assessments Leaf (Zytek)

8 Energy Efficiency Leaf (S Robinson JLR) Energy Consumption by Vehicle State (over 2 cumulative NEDCs) Energy Consumed / Wh 1% 9% 8% 7% 6% 5% 4% 3% 2% 1% % Whole Cycle Urban Extra-urban Time Distance Time Distance Time Distance % % % % % % Accel Decel Cruise Idle Acceleration Deceleration Cruise Idle Vehicle State Energy Consumed Extra-Urban NEDC Energy Consumed Urban NEDC 18 Energy / Wh Speed / kph Time / s Cold Extra-Urban (78 < t <= 118) 1 16 Hot Extra-Urban (196 < t <= 236) Scheduled Speed 14 8 Speed / kph 2 Cold Urban 1 ( < t <= 39) Cold Urban 2 (39 < t <= 78) Hot Urban 1 (118 < t <= 157) Hot Urban 2 (157 < t <= 196) Scheduled Speed Energy / Wh Time / s 3 2 4

9 Energy Efficiency Volt (Integral Powertrain)

10 Braking Assessment Volt (MIRA)

11 Aerodynamics Leaf Anti-Drag Lips

12 Aerodynamics Under body panels

13 Teardown Completed at JLR Gaydon facility Primary objectives > Permit viewing of EV and hybrid components in situ > Liberate key components for teardown

14 Teardown - Nissan Leaf

15 Teardown - Chevrolet Volt

16 Teardown - Nissan Leaf Motor

17 Summary Partners able to subjectively evaluate two new to market cars In depth evaluations completed in a broad range of activities Teardown enabled component level benchmarking Cars available post project to support partners and University based tuition and research

18 NVH Challenges of Alternative Powertrains Nathan Gabbott Principal NVH Engineer Tata Motors European Technical Centre

19 NVH Challenges of Alternative Powertrains Comparison of NVH characteristics of Electric and IC Engine driven vehicles Specific Challenges in Electric Vehicles Integration refinement of an APU into the vehicle

20 Comparison of NVH characteristics of Electric and IC Engine driven vehicles EV vehicles bring many new challenges to the NVH engineer: Reduced low frequency noise Increased high frequency noise Reduced load dependency Increased road and wind noise sensitivity However advantages can be found Reduced overall levels for improved passenger comfort

21 Comparison of NVH characteristics of Electric and IC Engine driven vehicles Nissan Leaf exhibits strong whine orders from transmission spur gears km/h 12 Nissan Leaf Hz 4 db(a) Hz 4 db(a) Hz 6 db(a) 2 Interior Noise Wide Open Throttle km/h Chevrolet Volt km/h IC Competitor Strong lower order content found in the IC engine is absent in the EV drives, reducing overall level at the cost of a less balanced overall sound quality

22 Comparison of NVH characteristics of Electric and IC Engine driven vehicles Both the Leaf and Volt exhibit noise from the power switching electronics between 8 and 12kHz These switching frequencies present a new challenge in the development of body sealing and trim packs due to their high frequency km/h 12 Nissan Leaf Hz Hz 1 db(a) 144 db(a) Hz db(a) 15 Interior Noise Wide Open Throttle km/h Chevrolet Volt km/h 12 IC Competitor 16

23 Comparison of NVH characteristics of Electric and IC Engine driven vehicles Interior Noise 8 Nissan Leaf Chevrolet Volt IC Competitor 3rd Gear 7 Pa db(a) Full Load 5% Throttle % Throttle km/h Neither the Leaf or the Volt show significant load dependency, this leads to a disconnected feeling from the vehicle.

24 Comparison of NVH characteristics of Electric and IC Engine driven vehicles Masking Noise Nissan Leaf 7 Chevrolet Volt 68 IC Competitor Road Noise 5km/h Road Noise 8km/h Wind Noise 1km/h Wind Noise 14km/h The Volt and Leaf have similar road and wind noise to traditional vehicles

25 NVH Challenges of Alternative Powertrains Comparison of NVH characteristics of Electric and IC Engine driven vehicles Specific Challenges in Electric Vehicles Integration refinement of an APU into the vehicle

26 Specific NVH Challenges EV vehicles have a number of specific issues that require attention, for example: Auxiliary Devices Vacuum pumps for brake assist Battery contactor noise at key on/off Pedestrian Awareness Nissan Leaf exterior sound source Chevrolet Volt Active Warning

27 Specific NVH Challenges The Volt has a strong multi order characteristic from the vacuum pump Vacuum Pump Off Vacuum Pump Noise Vacuum Pump Running

28 Specific NVH Challenges The Nissan Leaf has significant noise from the battery contactors at key on Nissan have created key on effects for the vehicle to help minimise the disturbance from these noises Key On Effects Off Contactor Noise Key On Effect 1 On

29 Specific NVH Challenges The Nissan Leaf includes an exterior sound source system to improve safety for pedestrian, particularly the blind and partially sighted The majority of the additional energy is added between 2 and 1Hz with a swept tone up to 23Hz Exterior Sound Source Off Pedestrian Awareness Exterior Sound Source On

30 Specific NVH Challenges Pedestrian Awareness The Volt does not have an always on exterior sound source fitted However an additional warning mechanism is included - when the headlight main beam is flashed the vehicle horn is cycled rapidly to provide a less intimidating warning than the main horn This warning is effective whilst being less aggressive to road users not isolated from the horn by a vehicle body

31 NVH Challenges of Alternative Powertrains Comparison of NVH characteristics of Electric and IC Engine driven vehicles Specific Challenges in Electric Vehicles Integration refinement of an APU into the vehicle

32 Integration refinement of an APU into the vehicle Powertrain Layout of the Chevrolet Volt Planetary Gearset ICE Generator Ring Carrier Traction Motor Sun Intermediate shaft Diff W H E E L

33 Integration refinement of an APU into the vehicle The plot below shows how APU speed in range extended mode is a function of power demand The APU appears to be run at or near full load in all conditions with the speed being altered according to the power demand This causes an odd subjective feel during over run conditions, with the APU labouring whilst the vehicle slows down 5 APU Speed vs. Road Speed 4 rpm 3 1% Throttle 5% Throttle % Throttle (Run Down) km/h

34 Integration refinement of an APU into the vehicle The start up of the APU in the Volt is very well managed, imperceptible in normal driving conditions The use of the second motor/generator unit allows the IC engine to be spun up to operating speed before it is fired, eliminating the kick usually experienced in IC only vehicles A similar strategy has been employed on shut down 4 35 APU Start Up Road Speed APU rpm PT Vertical Vibration Drivers Seat Rail Vertical Vibration km/h m/s s rpm 3 2

35 Thermal Benchmarking of the Nissan Leaf and Chevrolet Volt David Bridge MIRA Ltd

36 Tests Conducted Benchmarking covered > Body Leakage > Installed Airflows > HMI > Subjective Appraisals > Climatic Wind Tunnel Tests

37 CWT Testing Power performance > WOT throttle tests Cooling system related > Gradient climbs > City drive cycles > Vmax HVAC related > AC system performance > Heater system performance > Screen (defrost) clearing

38 LC Vehicle Testing Challenges Electric AC compressors & PTC heaters Independent cooling circuits Battery regeneration post test Battery temperature vs test time Heater performance test (15rpm) Pre-conditioning PWM pumps and fans Auto vs manual HVAC settings Amount of instrumentation (Volt)

39 Volt Coolant Circuits

40 Volt Coolant Circuits

41 WOT Test Leaf vs Volt: Force at WOT 7 Leaf Dyno Limit 6 Volt - Battery Only Volt - Battery and Engine Dyno Force - N 5 4 Engine On Speed - mph

42 WOT Test Leaf vs Volt: Developed Power at WOT 12 Engine On 1 Dyno Power - kw Leaf Volt - Battery Only 2 Volt - Battery and Engine Speed - mph

43 Body Leakage

44 Body Leakage Leaf vs Volt Cabin Pressure Drop Characteristics 8 Leaf 7 Volt Body Leakage Leaf: 43.6 cm2 Volt: 29. cm2 6 Air Flow - l/s Pressure Drop - Pa

45 Installed Flows: Face Vents Leaf vs Volt Face Vent Characteristics 12 Leaf Volt 1 Air Flow - l/s Blower Setting (%)

46 Installed Flows: Floor Vents Leaf vs Volt Floor (Hot) Vent Characteristics 12 Leaf Volt 1 Air Flow - l/s Blower Setting (%)

47 Installed Flows: Defrost Vents Leaf vs Volt Defrost (Hot) Vent Characteristics 12 Leaf Volt 1 Air Flow - l/s Blower Setting (%)

48 HMI - Leaf

49 HMI - Volt

50 CWT Testing 45 C AC Pull Down 45 C Mumbai city drive 45 C Vmax and idle 49, 38, 25, -5 C EUCD drive cycles 45 & 25 C max acceleration cycles GL4 12% Gradient at 4kph (3 C) - GG GL1 7% at 1kph (38 C) DD GL6 8% at 6 kph (38 C) -2 C heater warm-up -8 C screen defrost WOT tests

51 CWT Testing

52 AC Pull-Down Vehicle soaked to 45 C Volt plugged in overnight but charger failed after 16miles Solar load at 1W/m2 for 4 hours 6 kph 4 minutes 8 kph 3 minutes Static 2 minutes HVAC > Full fans > Full cold > Face mode > Recirculation

53 AC Pull-Down Av Interior Temperatures - 45 C AC Pull-Down (Volt vs Leaf) Temperature - C 8 7 Average Interior (GM Volt) 6 Average Interior (Nissan Leaf) Time - Minutes 8 1

54 AC Pull-Down Av Interior Temperatures - 45 C AC Pull-Down (Volt vs Leaf) 8 4 Average Interior (GM Volt) Average Interior (Nissan Leaf) Engine Speed Temperature - C Time - Minutes 8 1 Engine Speed - rpm 7

55 AC Pull-Down Av Face Vent Outlet Temperatures - 45 C AC Pull-Down (Volt vs Leaf) Temperature - C 8 7 Average Face Vents (GM Volt) 6 Average Face Vents (Nissan Leaf) Time - Minutes 8 1

56 Heater Warm-Up Vehicle soaked to -2 C Volt plugged in overnight 5 kph 6 minutes 1 kph 3 minutes Static 2 minutes HVAC > Full fans > Full hot > Foot vents > Fresh air

57 Heater Warm-Up Average Interior - -2 C Heater Warm-Up (Volt vs Leaf) 5 4 Temperature - C Average Interior (GM Volt) -1 Average Interior (Nissan Leaf) Time - Minutes

58 Heater Warm-Up Floor Outlet Temperatures - -2 C Heater Warm-Up (Volt vs Leaf) Temperature - C LHS Floor Outlet (GM Volt) 1 RHS Floor Outlet (GM Volt) LHS Floor Outlet (Nissan Leaf) RHS Floor Outlet (Nissan Leaf) Time - Minutes

59 Heater Warm-Up Floor Outlet Temperatures - -2 C Heater Warm-Up (Volt vs Leaf) LHS Floor Outlet (GM Volt) RHS Floor Outlet (GM Volt) LHS Floor Outlet (Nissan Leaf) 5 RHS Floor Outlet (Nissan Leaf) -1 Engine Speed Time - Minutes Speed - rpm Temperature - C 4

60 Conclusions Testing of EV and HEV type vehicles offers unique challenges Both vehicles communicate to user impact of HVAC choice on energy use Close attention to sealing of body and FEM on Volt Leaf delivers more installed airflows AC performance similar Cabin warm-up for Leaf is very poor Cabin warm-up for Volt much better (temp) but depends on engine switching and is subjectively poor

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